Method of assembling carton blanks

ABSTRACT

A carton is described having four serially rectangular panels each with a respective flap at either end. The first and second flaps form innermost flaps and lie opposite one another across the mouth of the carton end. The third and fourth flaps are each situated between the first and second flaps and form intermediate and outermost end flaps, respectively. The first and second flaps each have side portions lying adjacent the hinge line of the third flap and the third panel which taper generally upwardly and inwardly in a generally straight line from the third flap when the first, second and third flaps are all substantially parallel to their respective panels. The third flap has two tabs cut in its surface which are generally in the form of half circles and which are adapted to underlie and hold an end portion of the first and second flaps when the first, second and third flaps lie generally perpendicular to their respective panels in their closed position.

United States Patent [191 Cupo [ Dec. 16, 1975 1 METHOD OF ASSEMBLING CARTON BLANKS [76] Inventor: William J. Cupo, 216 York St.,

Jersey City, NJ. 07302 [22] Filed: Sept. 12, 1974 [21] Appl. No.: 505,220

Related US. Application Data [62] Division of Ser. No. 297,921, Oct. 16, 1972, Pat. No.

[52] US. Cl. 93/49 M; 93/53 LP [51] Int. Cl. B3113 49/02 [58] Field of Search 93/49 R, 49 M, 52, 53 LF, 93/53 M; 229/39 R [56] References Cited UNITED STATES PATENTS 2,053,857 9/1936 Weiss r. 229/39 R 2,151,733 3/1939 Bonfield 229/39 R 3,163,347 12/1964 Bixler 229/39 R 3,580,477 5/1971 Roth r. 229/39 R Primary Examiner-Roy Lake Assistant E.ranziner.lames F. Coan Attorney, Agent, or Firm-Brumbaugh, Graves, Donohue & Raymond [57] ABSTRACT A carton is described having four serially rectangular panels each with a respective flap at either end. The first and second flaps form innermost flaps and lie opposite one another across the mouth of the carton end. The third and fourth flaps are each situated between the first and second flaps and form intermediate and outermost end flaps, respectively. The first and second flaps each have side portions lying adjacent the hinge line of the third flap and the third panel which taper generally upwardly and inwardly in a generally straight line from the third flap when the first, second and third flaps are all substantially parallel to their respective panels. The third flap has two tabs cut in its surface which are generally in the form of half circles and which are adapted to underlie and hold an end portion of the first and second flaps when the first, second and third flaps lie generally perpendicular to their respective panels in their closed position.

3 Claims, 8 Drawing Figures U.S. Patent Dec. 16, 1975 POWER SOURCE FIG. 2

U.S. Patent Dec. 16, 1975 Sheet2of3 3,926,096

FIG. 3

XZ LW Q9 U.S. Patent Dec. 16, 1975 Sheet30f3 3,926,096

METHOD OF ASSEMBLING CARTON BLANKS This is division of application Ser. No. 297,921, filed Oct. 16, 1972, now U.S. Pat. No. 3,871,571.

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is a carton having four serially connected rectangular panels with flaps at the end of the panels having interlocking means thereon, a planar carton blank adapted to form the carton and a method for forming the carton.

2. Description of the Prior Art Representative examples of prior art cartons having end flaps with interlocking means thereon are disclosed in U.S. Pat. Nos. 3,074,613; 466,792; 1,968,082; 1,288,895; 2,151,733; 2,053,857; and 2,337,039; French Patent No. 1,063,100 and German Patent No. 1,068,174.

SUMMARY OF THE INVENTION The present invention includes a carton which is more easily assembled by machine, having four serially connected rectangular panels each with a respective panel along the length of the panel end. In such cartons it is customary for the first and second end flaps, which lie opposite one another across the opening of the carton end, to form end flaps after they have been rotated downwardly so that they lie perpendicular to their respective panels. The remaining two end flaps, i.e. the third and fourth flaps, also lie on opposite sides of the carton mouth and form the outer flaps. The first and second flaps in the carton of the present invention have sides adjacent the hinge line of the third flap and panel which are each generally upwardly and inwardly tapered from the third flap when the first, second and third flaps are in an upstanding position substantially coplanar with their respective panels. The third flap has tab means cut in its surface which are adapted to underlie and hold a portion of the first and second flaps after the first, second and third flaps have been rotated inwardly and lie generally perpendicular to their respective panels. In the finally assembled carton the first and second flaps are the innermost end flaps, the third flap forms an intermediate end flap overlying the first and second flaps and the fourth end flap forms the outermost end flap, overlying the third flap.

The invention also comprises the planar carton blank which can be used in forming the carton, and the method of assembling the carton. The method comprises applying glue to portions of the inner surfaces of the third and fourth flaps after the respective panels have been joined together into a tubular body, positioning of the first, second and third flaps after the glue has been applied so that all are inwardly inclined over the carton mouth and at an angle to a line drawn perpendicular to their respective panels so that the tab means in the third flap is in position to engage the underside of a portion of the first and second flaps, and inward rotation of the first three flaps until all are substantially perpendicular to their respective panels and the tab means in the third flap is under a portion of the first and second flaps thereby holding the glued inner surface of the third flap securely to the outer surface of the first and second flaps. Finally, the rotation of the fourth, and outermost, flap inwardly until it is perpendicular to its respective panel brings it into gluing contact with portions of the outer surface of the third flap.

BRIEF DESCRIPTION OF THE DRAWINGS The present invention will be further understood by reference to the drawings wherein: I

FIG. 1 is a view showing the planar carton blank which can be used to form the carton of the present invention;

FIG. 2 is an end view showing the partially formed carton, and the apparatus which may be usedto seal one end of the carton;

FIG. 3 is a view similar to that of FIG. 2 from the side;

FIG. 4 is a plan view similar to the views of FIGS. 2 and 3;

FIGS; 5 and 6 are views showing apparatus which can be used in closing the carton of the present invention after glue has been applied to portions thereof;

FIG. 7 is a view showing the carton when the inner and intermediate flaps have been rotated into position; and

FIG. 8 shows the carton of the present invention after the closing operation has been completed.

DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION The planar carton blank 10 of the present invention is shown in FIG. 1, and it comprises four serially connected rectangular panels 11, 12, 13 and 14 which are connected to one another by hinge lines as shown in dot-dash in FIG. 1. Hereinafter, panels 11 and 13 will be referred to as first and second panels while panels 12 and 14 will be referred to as third and fourth panels, respectively. Attached to each panel 11-14 are carton end flaps 15-18 respectively. In a preferred embodiment they are at both ends of the blank 10 so that they will form both ends of the carton to be assembled therefrom. The flaps l5 and 17 are the first and second flaps for the carton whereas flaps 16 and 18 are the third and fourth flaps, respectively. The third and fourth flaps 16 and 18 alternate with the first and second flaps 15 and 17 along one marginal edge of the planar carton blank 10.

Attached to one end of the panel 14 of the carton blank is a narrow sealing panel 19 which is used when each of the panel members 11-14 are bent to a angle to one another along the respectivehinge lines to form a carton body having unsealed end flaps 15-18 at either end. This type of general arrangement of panels and flaps is well-known in the art. If desired, the planar blank 10 could be formed with the panels 11-14 and their respective flaps 15-18 being placed in a different sequential order in the planar blank 10. The sealing panel 19 would then be placed on one of the panels 11-14 lying adjacent one end of the blank 10. Such modifications in the order of the panels 11-14 are well within the skill of those in the art.

The first and second flap members 15 and 17 have side portions 15a and 17a, respectively, lying adjacent the hinge line between the third flap 16 and the third panel 12 which are generally straight and upwardly and inwardly tapered from the third flap 16 when all three flaps 15-17 are in a position which is substantially coplanar with their respective panels 11-13 when the'flap 19 has been glued to the panel 11. The inward and upward taper of the first and second flaps 15 and 17 allows an at least partial inward rotation of the third flap 16 so the tab means on that flap can make sealing contact wth the first and second flaps 15 and 17 as described below. In order to provide a greater degree of sealing at the edges of the first and second flaps l5 and 17, shoulders b and 17b, which are approximately five thirty-seconds of an inch in height in a preferred embodiment of the invention, are provided in each flap. Corresponding parts and members 15'18, 21, l5a, 15b, l7a and 17 b are shown at the other end of the carton. 1

Two tabs 21 preferably in the form of half-circles are provided approximately midway between the hinge line joining the third flap 16 and the third panel 12 and the outer edge 22 0f the third flap 16. As shown in FIG. 1, eachof the tabs 21 is connected to the third flap 16 by a hinge line 23, substantially perpendicular to the hinge line'of-the flap 16, which lies approximately one-third of the way across the length of panel 16 from the end 24 of the panel16 nearest the circular edge of the tab. The distance of the hinge line 23 from the edge 24 of flap 16 will generally be about equal to the length of the flap 15 to permit proper mating of the two in closing the carton end. The same is true for the location of the other tab 21 with'respect to flap 17.

To assemble the carton of the present invention, the carton blank shown in FIG..1 is formed into a tube with each panel 1 1l4 perpendicular to its adjacent panels, and then joining sealing flap 19 to a marginal portion of the first panel 11. The flaps l5.18 are then in the position and each is in the plane ofits respective panel.

In orderthen to seal the end flaps, glue is first applied to portions of the third and'fourth flaps 16 and 18, respectively,the opposite end of the carton having been closed by suitable means, preferably means similar to that herein described. Apparatus for this operation is shown in FIGS. 2 through 4. The partially formed carton 25 is placed on a conveyor apparatus 26 so that it is passedunder a glue roller assembly 27. The third and fourth flaps are substantially horizontal to allow them to come into contact with the undersurface of the glue roller assembly 27. This is best shown in FIG. 4. At this point, the first and second flaps 15 and 17 are in the folded'configuration shown in FIG. 4. 1

The roller assembly 27 comprises three rollers 30, 3 and 32. Roller 30 applies the glue to surfaces 29. Roller 32'is mounted so that its surface is about one thirtysecond inch above the upper surfaces29 of the flaps l6 and 18'when thelatter are substantially horizontal as shown: The roller 31 is mounted somewhat higher than the roller 32so that it does not touch the flaps, and-the roller. 30 is mounted so that it touches the surface 29 of the flaps 16 and 18 when they are substantially horizontal.

As the carton 25 travels along the conveyor belt it alsocontacts the switch 33 to activate the solenoid 34 therebypushing attached piston 35 and the arms 36a and 36b upwardly so that the arms punch the tab means 21 upwardly, enabling them to later underlie a portion of first and second flaps 15 and 17. The under surface of roller- 32 provides. a support to hold the flap 16 against upward movement of the plungers or pistons 36a and 36b. As the carton 25 moves a short distance further it touches a deactivation switch 37 which retracts the piston 35 to its normal rest position thereby pulling the arms 36a and 36b out of the holes formed by the moving of the tabs 21 out of the plane of the flap 16.

The location of the wires which carry the electric current to the switches 33 and 37 and solenoid 34 is of course schematic and is such as to pennit movement of the carton 25. Moreover, the location of the switch 37 is such as to permit clearance of the pistons 36a and 36b in retracting from the holes in flap 16. If desired, the circuitry may be so designed that the switch 33 and solenoid 34 cause upward movement of the pistons for a time sufficient to raise the flaps 21 and also downward movement of the pistons in time to afford clearance of the flaps 16, without the need for providing the switch 37; In this way the switch 37 may be dispensed with.

After the inner surface 29 of the flaps l6 and 18 has been coated with glue, and the tabs 21 have been lifted so that they protrude from the surface of the flap 16, the carton 25 is advanced to means which perform the remaining operations of carton end closing or respectively. In FIG. 5 a guide bar 40 has a raised portion 41 which allows the innermost flaps 15 and 17 to rise to a position where they lie at an acute angle to the horizontal through natural reaction of the cardboard. In this position they are adapted to mate with the now inwardly protruding tabs 21 in the third flap 16. Conventional means (not shown) are used to rotate the third flap 16 so that it is also inclined inwardly towards the open end of the carton thereby allowing the inwardly protruding tab means 21 to make contact with an end portion 43 of the flaps l5 and 17 as shown in FIG. 6. The further continued rotation inwardly of flap 16 by means of an appropriately dimensioned guide bar will rotate the flap 16 inwardly and carry the tab 21 along the edge portion 43 of the flaps 15 and 17 thereby forcing all three flaps downwardly and inwardly until they are substantially perpendicular to their respective panels. The position is shown in FIG. 7. At this point, the glue which has been applied to the interior surface 29 of the flap l6 securely bonds it to the outer surface of the innermost flaps 15 and 17. The rotation of the outermost flap l8 downwardly and inwardly is then begun and is continued until its inner surface 29, which is coated with glue, is securely attached to the upper surface of the intermediate flap 16. The construction shown on the top of FIG. 8 is thereby formed.

It will beobserved particularly from FIG. 7 that in the assembled carton, the first and second flaps 15 and 17 substantially completely overlie the respective tabs 21, and the first and second flaps do not extend above the top surface of the third flap 16 through the openings formed by the tabs 21. I

FIG. 8 shows a preferred embodiment of the invention in which both ends of the carton 25 have the tab and flap arrangement of the present invention. If desired, only one end need be provided with such a construction, the other end being closed in a conventional manner.

Upon reading the specification and claims a person in the art will undoubtedly become aware of modifications that can be made merely by the exercise of ordinary skill in the art. Hence, the foregoing is intended to be merely illustrative of a number of preferred embodiments of the invention and is not to be construed as limiting. The scope of protection desired is set forthin the appended claims.

I claim:

1. A method of assembling a carton having four serially connected rectangular panels and four flaps at one end of the carton with each flap being hinged to a panel along the length of the panel end, a first of said flaps being joined to the first of said panels, the second of said flaps being joined to a second of said panels spaced from saidfirst flap by third and fourth flaps which are joined to third and fourth panels, respectively, said first and second flaps being bent inwardly perpendicular to their respective panels to form inner flaps for the carton end, said third flap lying generally over both the first and second flaps perpendicular to its respective panel and glued to said first and second flaps, and said fourth flap overlying at least a portion of said third flap to form an outer flap for the carton end perpendicular to its respective panel and being glued to said third flap, said first and second flaps having a side lying adjacent the hinge line of the third flap and third panel which tapers generally upwardly and inwardly from said third flap when the first, second and third flaps are in a position which is substantially coplanar with their respective panels and tab means cut in the surface of the third flap which underlie and hold a portion of said first and second flaps, said tab means being joined to said third panel by hinge lines which lie in a direction traverse to the hinge line of said third flap, comprising applying glue to inner portions of said third and fourth flaps, pushing said tabs in said third flap so that they protrude from the surface of the third flap and are thereby adapted to engage and underlie a portion of the first and second flaps, positioning the first, second and third flaps so that they are inwardly inclined to the mouth of the carton and the tab means in said third flap is in position to engage the underside of a portion of the first and second flaps, rotating the first, second and third flaps inwardly until all three flaps lie substantially perpendicular to their respective panels and the tab means in the third flap is under a portion of the first and second flaps and the third flap is thereby glued to portions of the first and second flaps, and rotating the fourth flap inwardly until it also is perpendicular to its respective panel and is glued to portions of said third flap.

2. A method for assembling a carton having four serially connected rectangular panels and four flaps at one end of the carton with each flap being hinged to a panel along the length of the panel end, a first of said flaps being joined to the first of said panels, a second of said flaps beingjoined to a second of said panels spaced from said first flap by third and fourth flaps which are joined to third and fourth panels, respectively, said first and second flaps being bent inwardly perpendicular to their respective panels to form inner flaps for the carton end, said third flap lying generally over both the first and second flaps perpendicular to its respective panel and glued to said first and second flaps, and said fourth flap overlying at least a portion of said third flap to form an outer flap for the carton and perpendicular to its respective panel and being glued to said third flap, said first and second flaps having a side lying adjacent the hinge line of the third flap and the third panel which tapers generally upwardly and inwardly from said third flap when the first, second and third flaps are in a position which is substantially coplanar with their respective panels, and tab means cut in the surface of the third flap which underlie and hold a portion of said first and second flaps, said tab means comprising two spaced tabs joined to the panel by respective hinge lines which lie in a transverse direction to the hinge lines of said third panel, comprising applying glue to inner portions of said third and fourth flaps, positioning the first, second and third flaps so they are inwardly inclined towards the mouth of the carton and the tab means in said third flap is in position to engage the underside of a portion of the first and second flaps, rotating the first, second and third flaps inwardly until all three flaps lie substantially perpendicular to their respective panels and the tab means in the third flap is under a portion of the first and second flaps and the third flap is over the first and second flaps and the third flap is thereby glued to the first and second flaps, said tab means underlying that portion of the first and second flaps lying adjacent the edge of the flap which is opposite the hinge line of the first and second flaps with their respective panels, said first and second flaps substantially completely overlying said respective tabs, and said first and second flaps not extending above the top surface of said third flap, and rotating the fourth flap inwardly until it also is perpendicular to its respective panel and is glued to portions of the third flap.

3. A method as claimed in claim 2, wherein before so positioning said first, second and third flaps, the tabs in the third flap are moved so that they protrude from the surface of the third flap and are thereby adapted to engage and underlie a portion of the first and second flaps. 

1. A method of assembling a carton having four serially connected rectangular panels and four flaps at one end of the carton with each flap being hinged to a panel along the length of the panel end, a first of said flaps being joined to the first of said panels, the second of said flaps being joined to a second of said panels spaced from said first flap by third and fourth flaps which are joined to third and fourth panels, respectively, said first and second flaps being bent inwardly perpendicular to their respective panels to form inner flaps for the carton end, said third flap lying generally over both the first and second flaps perpendicular to its respective panel and glued to said first and second flaps, and said fourth flap overlying at least a portion of said third flap to form an outer flap for the carton end perpendicular to its respective panel and being glued to said third flap, said first and second flaps having a Side lying adjacent the hinge line of the third flap and third panel which tapers generally upwardly and inwardly from said third flap when the first, second and third flaps are in a position which is substantially coplanar with their respective panels and tab means cut in the surface of the third flap which underlie and hold a portion of said first and second flaps, said tab means being joined to said third panel by hinge lines which lie in a direction traverse to the hinge line of said third flap, comprising applying glue to inner portions of said third and fourth flaps, pushing said tabs in said third flap so that they protrude from the surface of the third flap and are thereby adapted to engage and underlie a portion of the first and second flaps, positioning the first, second and third flaps so that they are inwardly inclined to the mouth of the carton and the tab means in said third flap is in position to engage the underside of a portion of the first and second flaps, rotating the first, second and third flaps inwardly until all three flaps lie substantially perpendicular to their respective panels and the tab means in the third flap is under a portion of the first and second flaps and the third flap is thereby glued to portions of the first and second flaps, and rotating the fourth flap inwardly until it also is perpendicular to its respective panel and is glued to portions of said third flap.
 2. A method for assembling a carton having four serially connected rectangular panels and four flaps at one end of the carton with each flap being hinged to a panel along the length of the panel end, a first of said flaps being joined to the first of said panels, a second of said flaps being joined to a second of said panels spaced from said first flap by third and fourth flaps which are joined to third and fourth panels, respectively, said first and second flaps being bent inwardly perpendicular to their respective panels to form inner flaps for the carton end, said third flap lying generally over both the first and second flaps perpendicular to its respective panel and glued to said first and second flaps, and said fourth flap overlying at least a portion of said third flap to form an outer flap for the carton and perpendicular to its respective panel and being glued to said third flap, said first and second flaps having a side lying adjacent the hinge line of the third flap and the third panel which tapers generally upwardly and inwardly from said third flap when the first, second and third flaps are in a position which is substantially coplanar with their respective panels, and tab means cut in the surface of the third flap which underlie and hold a portion of said first and second flaps, said tab means comprising two spaced tabs joined to the panel by respective hinge lines which lie in a transverse direction to the hinge lines of said third panel, comprising applying glue to inner portions of said third and fourth flaps, positioning the first, second and third flaps so they are inwardly inclined towards the mouth of the carton and the tab means in said third flap is in position to engage the underside of a portion of the first and second flaps, rotating the first, second and third flaps inwardly until all three flaps lie substantially perpendicular to their respective panels and the tab means in the third flap is under a portion of the first and second flaps and the third flap is over the first and second flaps and the third flap is thereby glued to the first and second flaps, said tab means underlying that portion of the first and second flaps lying adjacent the edge of the flap which is opposite the hinge line of the first and second flaps with their respective panels, said first and second flaps substantially completely overlying said respective tabs, and said first and second flaps not extending above the top surface of said third flap, and rotating the fourth flap inwardly until it also is perpendicular to its respective panel and is glued to portions of the third flap.
 3. A method as claimed in claim 2, wherein before so positioning said first, second and third flaps, the tabs in the third flap are moved so that they protrude from the surface of the third flap and are thereby adapted to engage and underlie a portion of the first and second flaps. 